Sealed joint for conductors



Aug. 15,1939. v, L, RONC, 2,169,570

SEALED JOIN'['- FOR CONDUCTORS Filed April 23, 1936 IN VE' N TOR y IKLRONCI QM ATTORNEY sleeve and the cable sheath at strains are apt to occur due to-dlflerence/ln expension and contraction of the-sleeve/and the Patented Aug. 15,1939

PATENT OFFICE SEALED JOINT FOR ooNnUcTons Victor L. Ronci, Brooklyn, N. Y., assignor to Bell Telephone Laboratories, Incorporated, New York, N. K, a corporation of New York Application April 23,

14 Claims.

This invention relates to sealed joints for con ductors and a method of forming the same, and more particularly. to the sealing. of a conductor subjected to high external pressures or excessive hydrostatic pressures.

An object of this invention is to hermetically seal the joint between a conductor and a casing of a cable or other apparatus, particularly a cable employed in transoceenic communication systems.

Another object of the invention is to permit the coupling of associated apparatus to an undersea cable without endangering theintemal elements of the apparatus or cable by corrosion or leakage.

In accordance with one embodiment of this invention, the seal is utilized for a terminal connection for a cable or other apparatus subject to high hydrostatic pressure encountered at deep sea levels and comprises a central conductor hermetically sealed to the inner wall of an insuiating mass or sleeve member. A thick walled metallic member, casing or cable sheath surrounds the sleeve and is provided with a thin wall portion at one end and a tapered wallportion intermediate the thin wall and the thick wall 01 the casing. The thin wall end portion is hermetically sealed to the outer surface of the sleeve over a distance corresponding to the length of the seal-between the conductor and the inner wall of the sleeve. This arrangement provides an impervious and permanent seal which is cable of withstanding extreme pressures usually encountered at deep sea levels. 2

A feature of the invention relates to the interposition of a pressure relieving or cushion material between the tapered portion of the casing and the insulating sleeve member from a point in alignment with the termination of the seal to the inner end of the sleeve to aid in supporting the reduced diameter wall portion of the casing to a point where the casing wall is sufdciently strong to withstand the hydrostatic pressure bearing against the casing.

A further featureof the invention relates to an additional function of the cushion material on the external surface of the sleeve member in which the foremost end of the material terminates the hermetic seal abruptly between the sheath. This point is reachedwhere thejfsheath wall increases in cross-sectlonptogsuch an"extentthat it is rigid and is lncapablfolfyleldlng, rapidly.

a point where 1936, Serial No. 75,927

to diflerences of expansion and contraction set up in the sleeve material.

Other features of the invention are concerned with the method of producing the impervious joint between the conductor and the sleeve and the sleeve and the sheath to withstand the hydrostatic pressures encountered at deep sea levels. These features embody the formation of the concentric and coextensive seals between the con ductor and sheath, the application of the-pressure relieving layer on the sleeve and various details of fabrication to produce a strong hermetic and non-corrosive insulated union between the conductor and the protective sheath of the cable.

The invention will be more clearly understood from the following detailed description when considered with the accompanying drawing:

Fig. 1 is a cross-sectional view of one embodiment of the invention prior to the final sealing operation and shows the relationship of the elements for producing the insulated conductor for a cable seal;

Fig. 2 is another view in cross-section of the seal of this invention showing the concentric joints after the final sealing operation.

Fig. 3 shows in cross-section a modification of the preliminary seal between the conductor and the insulating mass in which a bead is first fused to the conductor;

Flg. 4 illustrates the form of' the insulating mass on the conductor and shows a modified arrangement pt the cushion layer partly in crosssection;

Flg. 5 is another modification of the seal of this invention partly in section illustrating the location of a metallic ring on the insulating mass for terminating the sealing between the mass and the cable sheath; and

Fig. 6 is a. view in elevation of the completed cable seal as embodied in this invention.

The seal of this invention is primarily concerned with apparatus, such as transoceanic cable and other related equipment, which is located at great depths of the see. where enormous hydro: static pressures are encountered. In order to protect the cable from the corrosive action of sea water and also to maintain the electrical constants of the cable or associated apparatus stable. it is essential to prevent the entrance of sea water in the cable. Furthermore, the efliclency of the seal is dependent on the simplicity of assembly and,the elimination 01' cumbersome packing or *theuse of absorbent material which eventually decomposes due to corrosion.

Inaccordance with one 01' the aspects of this glass, commercially known as Pyrex or Non'ex" glass. The thickness of the glass mass will depend on the pressures existing in the locality where the cable or other apparatus is to be laid. For instance, at extreme depths the pressure may attain a value between 10,000 to 12,000 pounds to the square inch and it will be necessary to apply the required thickness of glass mass to the conductor H) which will withstand the crushing pressure encountered at such depths. Another factor to be considered in producing aneilicient seal in accordance with this invention is the coefflcients of expansion and contraction of the conductor and the glass mass. The coefllcients of the metal should be substantially the same or as near as possible as the glass mass to effect a perfect union or weld when heated, to fuse these elements together and maintain a hermetic joint under the conditions of actual operation.

In conformity with the latter requirement, the predominant factor in the selection of the appropriate materials for the production of the seal of this invention may be either the conductor or the glass insulating mass. Naturally, if the paramount requirement is a glass mass having a crushing pressure of high rating, it will be essential to employ a Nonex glass having very hard properties, such as 702 P. glass. on the other hand, the conductor material may be the controlling factor and, in that event, it will be necessary to employ a'glass material having the same or substantially the same coefficients. As

examples of appropriate materials, the following glass which has coefllcients close to tungsten, so" that the conductor for the seal would be formed of this metal. If "Fernico is used as the conductor, a glass of higher coefilcients would be selected, such as 705 A0 boro-silicate glass.

In following the steps of fabricating the sealed joint of this invention, a preliminary seal is produced between the conductor l0 and the glass mass l l which is in the form of an elongated sleeve. It is preferable to provide a sleeve having an inside diameter closely simulating the diameter of the conductor Ill. The sleeve surrounds the conductor and heat is applied to the sleeve and conductor uniformly to prevent'stresses being set up'in the glassmass during fabrication. When the proper working temperature of the glass is reached, the intermediate portion of the glass mass, as shown at A in Fig; l, is heated to a plas tic state in order to wet the glass to the surface of the conductor l0 and form a hermetic weld or union therewith over the area indicated. After the preliminary seal is completed and the surface of the sleeve is made smooth and concentric with the conductor'by grinding or polishing, a thin layer 13 of pressure relieving material is applied overthe outer surface of the sleeve beyond the 3 preliminary seal as-shown at .B in Fig. 1. This layer may be in the form of a thin tubing of metal, such as copper, nickel or other suitable metal or alloy. The layer may also be applied on the sleeve by electrodeposition or applied as a film of material not readily wetted by glass in a plastic state, such as graphite. The layer should be relatively thin,.for instance, about .002 inch in thickamatwo ness. A method of gauging the thickness of the layer of pressure relieving material may be resorted to as-shown in Fig. 4 in which the outer portion of the sleeve II is undercut by grinding end of the sheath intended to be hermetically sealed to the glass is reduced in thickness to a fine knife-like edge so that the portion I1 coextensive with the layer I3 is tapered to a greatly reduced diameter at the-termination of the line between A and B and the remaining portion I8 is gradually reduced in thickness until the edge is rendered sharp or knife-like and the portion I8 is very pliant. ment of the seal and the method of forming a hermetic seal with a glass element is more clear- 1y disclosed in W. G. Housekeeper, U. S. Patent 1,294,466 dated February 18, 1919.

When the knife edge taper is produced on the cable sheath l6,the coated conductor I0 is inserted in the sheath with the layer l3 in contact with the inner wall of the sheath over an area substantially coextensive with the tapered portion I! of the sheath while the knife-like portion l8 surrounds the area of the mass ll coextensive with the preliminary seal previously described. It will be noted that in the arrangement, as shown in Fig. l, the thin film or layer l3 causes the inner surface of the portion l8 of the sheath to be spaced away from the surface of the glass mass II. This is the relative position of the elements of the seal in the form of the invention being discussed prior to the final heating operation. A heating flame is applied to the glass mass II and the knife edge portion l8 of the sheath, and when the glass is rendered plastic the surface tension of the metal and glass causes the glass to adhere or weld to the thin metal portion l8 as shown in Fig. 2 and forms a permanent hermetic union or seal over the area designated A in Fig. '1. This produces two concentric and coextensive sealed conductor and the cable sheath to form aperfect- The tapering of the metallic elely insulated conductor connection for a cable capable of withstanding the hydrostatic pressures encountered at deep sea pressures.

The thin portion l8 of the cable sheath which has a coeflicient of expansion different from that of the glass is capable of adhering to the glass regardless of this difference in expansion due to the pliant nature of the metal up to a point where the metal is more rigid. Therefore, inaccordance with the invention, the thin film or layer of material l3 provides the means for terminating the seal between the glass and the metal abruptly at a point where the metal is not sumciently pliant to yield under conditions of stress caused by expansion and contraction and where the differences in expansion between the glass and the metal would cause abnormal strains which might fracture the glass or metal sheath and permit the entrance of moisture. The film or layer I3 of.

cushion material also has another useful function by protecting the portion-of the glass mass which it covers in relieving or cushioning the external pressure bearing against the tapered portion ll of the sheath over the area from the seal to the normal thick wall of the sheath. The layer I! reinforces the cable sheath portion II where it is of insufllcient thickness to withstand the external pressure to a point where the normal wall thickness of the sheath is sufllcient to withstand such pressures.

Any of the combinations of metal and glass, as previously described, may be produced by a method of procedure, as shown in Fig. 3, in which a glass bead I2 is first sealed or fused to the conductor and then the sleeve I i placed over the bead and fused thereto by heating. For instance, the tungsten, "Fernico or Dumet conductor may be provided with a bead of the appropriate glass having the proper coefiicients of expansion and contraction and then a sleeve ll of similar glass may be sealed to the bead as previously described.

In Fig. 5, another modification of the invention is shown in which the cushionlayer is omitted. In this form, the glass mass is provided with a groove [9 and a metallic split ring 20 is seated in the groove to terminate the seal between the glass mass 1 I and the thin portion ll of the cable sheath. The outer surface of the ring lies flush with the, unsealed surface of the mass H and this surface is in contact with the tapered portion ll of the sheath so that the external pressure ex-.

hydrostatic pressure which comprises a metallic.

casing having a thick walled portion, a conductor projecting from said casing, an insulating sleeve surrounding said conductor and having an internal portion thereof sealed to said conductor, said casing having a thin walled portion coextensive with the sealed joint between said conductor and said sleeve and being sealed to the exterior of said sleeve, an intermediate tapered portion connecting said thin walled portion and said thick walled portion 'of said casing, and a seal terminating member on said sleeve within said casing adjacent said thin walled portion.

2. Aninsulated conductor seal capable of sustaining hydrostatic pressures of the order encountered at oceanic depths which comprises a conductor, an elongated insulating sleeve engaging said conductor and having an intermediate portion thereof hermetically fused to the surface of said conductor, a wrapper of cushion material on said sleeve rearwardly of said fused inter mediate portion, and a thick walled metallic sheath surrounding said conductor, said sheath having a knife edge termination and a tapered portion intermediate said termination and thick wall, the knife edge portion being fused to said sleeve over an area coincident to said fused intermediate portion and said tapered portion engaging said cushion material.

3. An. insulated conductor seal for a cable connection capable of maintaining an impervious member and havingan intermediate portion thereof hermetically sealed thereto, a cable sheath surrounding said mass having a termination tapering to a knife edge portion, said portion being located along the exterior of said mass for a distance substantially coincident with the hermetically sealed portion and being sealed to said mass to form concentric and coextensive 1m pervious joints between said member, mass and.

Icable sheath, and means between said mass and cable? sheath for terminating the seal therebetween at a point where detrimental stresses occur.

4. An insulated conductor'seal for acable connection capable of maintaining an impervious joint under pressure conditions encountered at deep sea levels which comprises a central metallic member, an insulating mass closely engaging said member and having ntermediate portion thereof hermetically sealed thereto, a cable sheath surrounding said mass having a termination tapering to a knife edge portion, said portion being located along the exterior of said mass for a distance substantially coincident with the hermetically sealed portion and being sealed to said mass to form concentric and coextensive impervious joints betwen said member, mass and nection comprising a metallic conductor, an insulating sleeve engaging said conductor, a metallic cable sheath surrounding said sleeve and conductor, concentric hermetically sealed joints between said conductor and sleeve and said sleeve and sheath, and a seal terminating member on said sleeve adjacent the sealed joint between said I sleeve and sheath.

'7. An insulated conductor seal for a cable connection comprising a metallic conductor, an insulating sleeve engaging said conductor, a metallic cable sheath surrounding said sleeve and conductor, concentric hermetically sealed joints between said conductor and sleeve and said sleeve and said sheath, and a metallic layer between said sheath and sleeve adjacent the sealed joint therebetween.

8. An insulated conductor seal for a cable connection comprising a metallic conductor, a fixed insulating sleeve engaging said conductor, a metallic cable sheath surrounding said sleeveand conductor, concentric hermetically sealed joints between said conductor and sleeve and said sleeve and sheath, and a copper tubular member embracing said sleeve adjacent the sealed joint between said sleeve and sheath.

9. An insulated conductor seal for a cable connection comprising a metallic conductor, a fixed insulating sleeve engaging said conductor, a metallic cable sheath surrounding said sleeve and conductor, concentric hermetically sealed joints between said conductor and sleeve and said sleeve and sheath, and a layer of graphite material on said sleeve adjacent the sealed joint between said sleeve and sheath.

10. The method of forming a hermetically sealed insulated joint between a conductor and a diameter from said thin walled portion to the body of said casing; said tapered'wall portion lying adjacent said cushion material, sealing said thin wall portion to said sleeve, and terminating the latter sealing abruptly at the edge of said cushion material.

11. The method of hermetically sealing a conductor in a metallic sheath to withstand high pressures at sea floor levels which comprises, forming an internal fused joint between the conductor surface and an insulating sleeve in contact with said surface, surrounding said sleeve with a cushion layer beyond said fused joint, ap-

plying the metallic sheath over said layer, taperingsaid sheath gradually to a knife edge portion, and fusing said knife edge portion to the exterior of said sleeve over an area from the beginning of said internal fused joint to the edge of said cushion material.

12. In the manufacture of a seal for a conductor in a cable sheath to withstand high pressures at deep sea levels, which includes a central conductor concentric with the sheath, and insulating filler therebetween, and a pressure relieving material on said filler, the method which comprises, tapering said sheath for an extended length to a knife edge, supporting the tapered portion of said sheath on said filler by the pressure relieving material, producing concentric fused joints between said conductor and filler and between said filler and sheath over a definite area of length, and terminating the joint of said filler and knife edge portion abruptly at the adjacent edge of said material.

13. In the manufacture of 'a seal for a conductor in a cable 'sheath to withstand high pressures at deep sea levels, which includes a central conductor concentric with the sheath, an insulating filler therebetween, and a pressure relieving layer on said filler, the method which comprises tapering said sheath for an extended length to a knife edge, producing an internal seal between an intermediate portion of said filler and conductor, inserting the united conductor and insulating filler within the sheath, sealing said knife edge portion to said filler over an area coincident with said first'seal, and applying a pressure relieving layer to the surface of said filler from a point of the termination'of the seal between said filler and sheath over the area covered by the sheath portion of insuflicient thickness to. withstand external pressures encountered at deep sea levels to the sheath portion of suificient thickness to withstand such pressuresj 14. The method of hermetically sealing an insulated conductor in a metallic sheath to withstand high pressures at sea floor levels which comprises, fusing a glass bead to said conductor, heating an insulating filler vto closely surround said conductor and fuse to said bead, applying a metallic material to the exterior surface of said filler from a point in the plane ofthe termination of said bead to the end of said filler, inserting the insulated conductor within a cable sheath having a tapered wall terminating in a knife edge portion, heating said knife edge portion and filler over an area defined by said head, fusing said portion to said filler over said area, and terminating the fusion thereof at the portion and metallic material.

- VICTOR L. RONCI.

junction of said 

